Separation of solids



oct. 4, 1960 J. PAGNQTTI mL 2,954,870

SEPARATION OF SOLIDS Filed Oct. 22, 1957 INV ENTORS ATTORNEYS Unite SEPARATION F SOLIDS Joseph Ross Pagnotti, Old Forge, Pa., and Samuel Barron, West Long Branch, NJ., assignors to Mineral Processing Corporation, Dover, Del., a corporation of Delaware Filed ct. 22, 1957, Ser. No. 691,570

4 Claims. (Cl. 209-1725) eration of solids of dilierent specic gravities and of a wide size range can be eifected. The size range may be all or part of 6 X 1A and of a variable distribution.

Present gravity medium processes have proven of benefit for `the separation of particles of different specific gnavities Ifor sizes larger than 1A. In all of these processes, particles of diiierent specific gravities. are immersed `in a gravity or'heavy medium having a specific gravity higher than that of .the light fraction and lower than that of the heavy fraction. The separation is effected by the tendency of the lighter particles to oat and the heavier particles to sink.

ln practice, the heavy medium is prepared by making a suspension of cornminuted solids of high specic gravity in water. This suspension is substantially self sustaining with agitation. lt is essential, however, not only to maintain the specitic gravity of the medium uniform and constant, but also to introduce the feed, and discharge the sink and float fractions without interference with the fluid iiow conditions. These are prerequisite to the maintaining of optimum operating conditions.

.To meet these dem-ands, a number of types of separatoryvessels are in use. These are equipped with many mechanical devices such as agitators, sweeps, screws, chain and ilight conveyors, buckets, drags and rakes. By these devices, many problems are solved, but often new diiculties are introduced.

. Where the feed comprises a proportion of solids of nearly equal specific gravities such as is the case with anthracite coal, the eddy currents gener-.ated by these devices cause particles of a specific gravity somewhat higher than. the specific .gravity of separation to float with the lighter particles, and particles of a specific gravity somewhat lower than the specic gravity of separation to sink with the heavier particles, in either case impairing the eil'iciency of the separation.

1 Where the feed comprises a considerable proportion of the larger sizes, and includes solids of or 6 inch diameters, operational diiculties arise, often to the point at which the eiliciency is so impaired that the process is no longer of practical use. For example, in processes using a separatory vessel of the cone type, the removal of the sink fraction from the bottom through the necessarily large size conduit by means of an air lift, for example, requires the use of excessive and impractical amounts of air. The use of an elevator under these conditions often presents mechanical diculties.. More important, the huid ovv conditions in the separatory vessel may be so aifected -that a satisfactory separation is impossible. In other types of separatory vessels, equipped with drags, screws, rakes, etc., the fluid flow conditions are also affected and a satisfactory separation cannot be made.

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It will be observed that in all of these processes many and diverse mechanical devices are employed to produce and maintain the conditions necessary for an etdcient separation, but which are found wanting in the presence of a feed of wide size range or a feed which includes very large sizes.

Quite obviously, there is a need for a method and an apparatus that will provide a means for the treatment of particles of a wide size range, including a proportion of large pieces up to 6" in diameter, that will be ecient and economic Iand will not be subject to these diieulties.

It is the purpose of this invention to provide just such an ,apparatus and method that will satisfy this need for a means Ito separate solids of diiierent specic gravities, of very wide size range and avoid the various diculties and limitations `in other processes.

By t-he present invention, such `an Vapparatus is furnished. A method lis here disclosed which preferably makes use of Aan aqueous suspension of a heavy media of magnetic permeability, and which functions without the use of any mechanical devices to maintain the uniformity of the specific gravity of the medium, to remove the iloat fractiomor to remove the sink fraction from the separatory vessel.

Although this invention is especially well adapted to a process wherein the medium comprises a iinelydivided suspension of magnetically permeable solids such as magnetite or ferrosilicon, it is also applicable to a process wherein the medium may be a true liquid such as an aqueous salt solution of zinc chloride or calcium chloride or a heavy organic liquidV such as tetrabromethane (C2H2Br4), or bromotorm (CHBra).

When a medium of the suspension type is used, it is necessary that the specific gravity of the medium be maintained unito-rml Although this may be accomplished by the use of mechanical ,devices or by inducing an upward current of the medium, the latter is 'much superior since mechanical agitation often introduces eddy currents and other disturbances into the bath. The velocity of the upward current used should be less than the sink .rate of the heavier fraction and greater than the sink rate of the media solids.

The preferred separatory vessel is the conventional cone, provided with a wier to take the overflow at the top of the cone, a means of introducing medium to impart an upward current in the cone and to remove hydraulically the sink particles.

The features of this invention are: Y

l(l) The provision of ain efficient and economicprocess4 for the separation of solids of different speciiic gravities, having a -wide size range, including a proportion of solids las largeras 6 in diameter.

(2) The provision of a method and apparatus in` which the separation can be made using aliquid suspension of heavy media.

(3) The provision of an apparatus from which the light vand heavy fractions are-removed hydraulically.

(4) The provision of a means of discharging the sink fraction without atfecting iluid'ow conditions in the separator. c

(.5) 'Ihe provision of a non-mechanical means of maintaining aV uniform specific `gravity of the medium.

Other .and further `objects of the invention will become apparent from the following detailed description when taken with the sole `figure of the drawing which shows schematically the apparatus of the present invention. Y

Before referring to the drawing land setting forth a detailed description, the invention will first be described in general terms. The apparatus for this discussion will-be the preferred separatory vessel commonly knownas a The method of operation comprises the following steps in combination. A mixture of coarse particles, having a wide size range, .and 'a heavy medium of the desired specic gravity is introduced into a cone at a point on the periphery at the surface of a fluid mass of heavy medium (finely divided `solids in aqueous suspension). The fluid mass or bath is maintained in a substantially quiescent state and at a uniform specific gravity. Medium is also introduced into the cone at two additional points: (l) at the throat of thecone above the apex discharge point to impart a slight upv/ard movement of the medium in order to maintain the speciiic gravity uniform, and to transport hydraulically the sink particles into a receptacle which connects the apex of the cone to the discharge conduit, and (2) into the aforementioned receptacle to transport hydraulically the sink particles through the discharge conduit. The ow through this discharge conduit is produced by the' pressure head developed by the difference in elevation between the surface of the medium and the point of discharge.

The light fraction and medium are removed by overllowing a wier at the top of the cone at a point on the periphery opposite the feed. The heavyfraction and medium are discharged from the apex of the cone, through the conduit into a chute. The float and sink fractions are passed to other steps of the recovery process to recover and reclaim the heavy medium, but they rform no part of this invention.

In the above description, the fluid bath has been described as an aqueous suspension of finely dividedy solids. In practice, the huid bath is usually an aqueous suspension of magnetically permeable particles which are substantially self sustaining. Heretofore, the medium bath has been maintained at a uniform specic gravity throughout by mechanical agitation. In the present invention, agitation of this type would destroy the duid flow conditions.

The sole figure of the drawings is a Schematic representation of the separatory vessel showing in detail the novel features. Referring now to the gure, the invention will be described in terms of a preferred embodiment.

The separatory vessel comprises a conventional cone provided with a chute 11 for introducing the feed at one side of the cone, at the periphery, at or adjacent to the surface of the contained bath. A wier 12 is provided opposite the pointof feed for discharging the oat fraction into a launder or chute 13 for further processing. At the apex of the cone 10 is a relatively large opening V14 to which is connected a receptacle 15 in the shape of a frustum of a circular cone, the lower end of which is connected to a conduit 16.

This'discharge conduit 16 is in the shape of a long sweep U reversing the direction of the downwardly flowin'g discharge and carrying it upwardly to an elevation which will produce a velocity of the discharge in the conduit that will maintain the largest and heaviest particles in suspension. A chute 17 cooperates with the terminus of conduit 16 to receive and carry away the discharge or sink.

p The critical velocity increases with increase in sizeof the largest particleto be removed. Thus, the elevation of the point of free discharge designated in the drawing by the numeral 18, is governed by the size of the largest particles in the discharge and may bepredetermined.

The receptacle 1S is anV essential element. The diameter of its upper opening and that of the apex opening of cone 10 must be at least three times they longest dimension of the largest particles to avoid Apossible arching and consequent blockage of the flow. The diameterof the conduit 16 and the lower Opening of receptacle 1-5 must be at least twice the longest dimension of the largest particles 'to permit ready ow. They length ofthe receptacle 15 should be equal to at least six times the f diameter of the largest sink particle.v The Vconduit dis-r charges the sink fraction into chute or launder 1'7for` 1,v further processing to separate the sink from the heavy medium so that it can be circulated to a suitable sump or storage container 20 for"reuse. A valve 21 is provided for draining and cleaning purposes only.

The sump 20 is connected by conduit 22 to the inlet of pump 23. Conduit 24 connects t'ne discharge of pump 23 with the top of cone 10.v A short conduit 25 provided with a vcontrol valve 26 empties into the top of cone 10 at labout the same vpoint as the feed from chute 11. A- branch conduit 2S, provided With control valve 29,*is connected from conduit 24 to a point adjacent the apex of cone 1o. A second branch conduit 30, provided with control valve 31 is connected from conduit 24 to receptacle 15. The heavyk mediumcontained in sump 20 is thusy pumped to the top of cone A1t?, to a point adjacent the apex of cone 1t), and to receptacle 15.

For ease yof description, the method of operation will be explained as applied to the separation of anthracite coal, having `a specific gravity less than 1.65 from a refuse.l having a somewhat higher specific gravity. The size range is -lj x -l-ly. The media solids will be regarded as magnetically permeable magnetite having ay specific gravity of 5. Despite the specic references, it is not the intent :to limit the invention to the separation of coal from its refuse, nor to the use of magnetite. The selection of these materials is strictly by way of illustration and not for the purpose of restriction or limitation.

A feed comprising lanthracite coal and refuse of a size range 31/ x +1?;/16", for example, is introduced via chute y11 together with a heavy medium via conduit 25 at or adjacent to the .surface of the substantially quiescent medium bath 4l) contained in cone iii. The heavy medium is prepared with a liquid (water) to solids (magnet-ite) ratio `that will yield a specific gravity of 1.65.

The particles `of'coal of a specific gravity less than 1.65

iloat and are discharged from the cone separator over the wier 12 in the usual mannen A special technique, however, is used to remove the refuse particles-from4 the separatory cone 10. The refuse flows through the relatively large discharge opening 14 of `the cone into the receptacle 15 and `then through the conduit 16v discharging into a chute or launder 17` by means of medium injected into the cone 10 via conduit 28 and into the receptacle 15 via conduit 30. The quantity of medium introduced into the cone is such that an upward movement of the medium occurs in the zone above to maintain a uniform gravity of the medium and a downward movement roccurs in the zone below to prevent the accumulation of refuse, crowdingj and to carry thev sink material into the receptacle 15. The additional quantity of `medium* introduced into theA receptacle 15 furnishes the volume of medium required to provide the velocity necessary to maintain the largest particles in suspension inv the discharge conduit 16 without disturbing the lluid vilow conditions in the cone 10.

f The sink product (refuse) is discharged into the chuteor launder 17 for further processing or waste.

Although the `additional quantity of uid introduced into the receptaclelS to furnish the necessary volume is shown as circulating medium, another liquid, such as water, may here be used, because this liquid does not tale part in the separation.

`Fioin the above description, it will be `apparent that this .appar-atus andthe' method of its application furrushes' a novel device and method `for the removal of fthe-sink` material from the separatory vessel `and provides for maintaining the iiuid dow conditions for the 'trhcient and leconomic Iseparation Aof particles 'of difthat the cycle'of flow isfso rapid that at no time is there aideparture from optimum operating conditions. In `the anthracite industry, it is sometimes desirable `to subject Vthe-.refuse` from'theseparation to a second separation at a higher specific gravityin'order to recover valuable coal products from intermediate gravity'material which in the rst separation sank with the refuse. This intermediate gravity material usually consists .of particles which are part coal and lpart refuse. I-f these intermediate gravity particles are separated from the heavy refuse particles and then subjected to a grinding process, the valuable coal portion is broken away from the refuse portion and may be recovered by mixing with the raw feed to the first separation.

The following :specific example of the recovery of this intermediate'gravity material will illustrate the operation of the process. Refuse material of a size range 4" x `-i-5/16 is fed by means of a chute into an 8 foot separatory cone-at the rate of 100 net tons per hour or its liquid equivalent of 300 gallons per minute. Meliumof a specific gravity of 1.75 which has been circulating through the system for about iive minutes is now delivered to the same chute at the rate of 300 gallons per minute and the mixture of refuse material and medium is discharged into lthe medium bath at the surface. Medium of the same specific gravi-ty is introduced into the lower section of the cone atthe rate of 500 gallons per minute imparting 4an upward movement to the bath, and carrying the sink materialdownwardly into a receptacle designed in accordance with the principles laid down for the design of receptacle 15. Additional medium in the amount of 600 gallons per minute is introduced into the receptacle to transport the heavy refuse through a U-shaped discharge conduit to a discharge point spaced slightly below the level of the bath in the cone. By this means a velocity of 7 feet per second is imparted to the sink fraction owing through the discharge conduit. This velocity is required to maintain the large particles in suspension.

The light fraction (intermediate material) and medium overflows the wier at the top of the cone at the rate of 50 tons per hour, then is subjected to a washing and screening operation, followed by a grinding operation. The ground product is then mixed with the rawr feed and sent to the co-al separator.

T-he heavy fraction and medium is discharged from the U-shaped discharge conduit and then subjected to a washing and screening operation to recover the medium and nally sent to waste.

From the foregoing, it will be apparent that the .present invention possesses a number of important advantages. It permits the processing of a feed of wide size range and very large particle size in a very eicient and economic manner. It employs nti-mechanical devices to remove the float and sink products or to maintain uniformity of gravity. It permits of easy control.

The above described preferred separatory vessel and method of its application is novel. It is not, however, the intent to limit this invention to its use. Other type separatory vessels employing the same principles may be used.

Although the present invention hasbeen shown and described with reference to a preferred embodiment, nevertheless, various changes and modifications such as are obvious to one skilled in the art and Iwhich do not depart from the spirit, scope, and contemplation of the inventive thought herein embodied, are deemed to fall the boundaries of the invention.

What is claimed is:

l. A oat and sink process lfor separating a mixture of solids of different specific -gravities and of a Wide size range into a light fraction Yand a heavy fraction of said mixture, using a relatively quiescent bath containing a heavy medium and having a gravity substantially equal to the gravity of separat-ion, comprising the steps of introducing into the top of said bath a mixture of said solids together with a quantity of medium sufficient to carry the light fraction across the top of said bath, withdrawing the light fraction and medium 4from the top of said bath, withdrawing the heavy fraction and medium from the bottom of said bath in the form of a stream, said stream being directed downwardly from the bottom of said bath and then upwardly to a free discharge point located in elevation above the bottom and `below the top of said bath, the difference in elevation between said discharge point and the top of said bath being such as `to produce a resultant minimum stream velocity capable of carrying all of the sol-ids including the largest sized solids in said stream to said discharge point, introducing `a sucient quantity of medium into said bath at a level above the bottom thereof to establish a slight upward movement of the bath from said level thereby maintaining the specific gravity of the bath uniform without destroying the relatively quiescent condi-tion of the bath and also to convey the heavy fraction to the bottom of said bath, introducing uid Ainto said stream below the bottom of said bath and in a sucient quantity to satisfy the volume requirements of said stream at said resul-tant stream velocity without disturbing the conditions of said bath.

2. A oat and -sink process for separating a mixture of solids of different specific gravities and of a wide size range into a light fraction and a heavy fraction of said mixture, using a relatively quiescent bath containing a. heavy medium and having a gravity substantially equal to the gravity of separation, comprising the steps of introducing into the top of said bath =a mix-ture of said solids having -a particle size greater than about 1A"- and less than about 6 together with a firs-t quantity of medium suicient to carry the light fraction across the top of said bath, withdrawing the light fraction and medium from the top of said bath, withdrawing the heavy fraction and medium from the bottom of said bath in the form of a stream, said stream being directed downwardly from the bottom of said bath and then upwardly to a. free discharge point located in elevation Vabove the bottom and below the top of said bath, the difference in elevation between said discharge point and the top of said bath being such as to produce a resultant stream velocity capable of carrying all of the solids including the largest sized solids in said stream to said discharge point, introducing a second quantity of medium into said bath at a level above the bottom thereof in sucient amount to establish a slight upward movement of the -bath from said level thereby maintaining the specific gravity of the bath `uniform without destroying the relatively quiescent condition of the bath and also to convey the heavy fraction to the bottom of said bath, introducing a third quantity of medium into said stream below the bottom of said bath and in a suiiicient amount to satisfy the volume requirements of said stream at said resultant stream velocity without disturbing the conditions of said bath.

3. A oat and sink process for separating a mixture of solids of different specific gravities and of a wide size range into a light traction and a heavy fraction of said mixture, using a relatively quiescent bath containing a heavy medium and having a gravity substantially equal to the gravity of separation, comprising the steps of introducing into the top of said bath a mixture of said solids having a particle size greater than about 1A and less than about 6" together with a first quantity of medium sufficient to carry the light 'fraction across the top of said bath, withdrawing the light fraction and medium from the top of said bath, withdrawing the heavy fraction and medium from the bottom of said bath in the form of a stream havin-g a diameter equal to at least three times the diameter of the largest sized solids in said stream, reducingv said stream to a diameter of at least twice the diameter of said largest sized solids over a distance equal to at least six times the diameter of said largest sized solids, said stream being directed downwardly from the bottom of said bath and then upwardly to a free discharge point located in elevation above. the bottom and below the top of' saidv bath, the difference inelevation between said idisc'shar'ge pointy and. the topvof sairli .bath being such as to y'produce a resultantminimum stream velocity i tov` the bottom of said bath, introducing a third quantity y ofmedium-into said stream below the bottom ofsaid bath and in a suicientrarnount to satisfy the volumereqi-eznent'sof said' streamat said resultant strean velocity without disturbing the conditions of said bath.

T4. Floatiand sink apparatus for separatinga mixture of solidsof different specic gravities: and' of a wide size range finto a light lfraction and avheavy fraction of said mixture,fusing a relatively quiescent bath, containing a heavy medium and having a gravity substantiallyequalv to the gravity of separation, comprisingv a separating cone filled 'with said bath and having an open apex at the lower end of said cone,'means for introducing into the top of saidv cone va mixtureY of said solids having a particle size greater' than about 1A" and less than about 6"V together v'vitla vfirst quantity of medium suicient to carry the light fraction across the top of said bath, means for withdrawing the light fraction and medium from the top of said cone, a frusto-conical receptacle communicating with` the open apex at the bottom of said cone for withdrawing the heavy fraction and medium from the bottom ofy saidi cone in the `form of a stream, the upper end. of saidv {fusto-conical receptacle at its pointV ofconn'ection with 'the apex of said cone having an opening whose 35 diameter is equal to at least three times the diameter of the largest sized solids in saidstream; the lowerend of said'- frustofconical receptacle yhaving an opening whose diameter is equalto atleast twice thel diameter of saidy the lower opening of said truste-conical receptacle, said t streamy passingf'rom -said bath through saidl truste-conical receptacle through said U-shaped conduit to said point otffee discharge', the difference in elevation between said other end 'of said .LJ-shaped conduit and the. top` ofsaid conebeing such V-asjto produce a resultant minimum stream velocity capable of carrying all Yof the solids includingf said largest sizedl solidsin said stream to said discharge point, means for introducing a second-quantity ofY medium :into said bath at a level above thewbottom of said cone' insufficient amount to establish a slight upward movement of theY bath from said level, thereby maintaining the specific gravity of the bath uniform without destroying the relatively quiescent condition thereof, and-also to convey the heavy lfraction to the bottom of said cone, fand means for introducing a third quantity of medium into said frusto-conical receptacle and in a sufficient amount tosatisfy the volume requirements of said stream at said resultant stream velocity without disturbing the conditions of said bath.

References Cited in the le ofvthis patent UNITED STATES PATENTS 

